Random texture pile fabric



July 1, 1958 D. KARPOFF ET Al. 2,841,187

RANDOM TEXTURE PILE FABRIC Filed Jan. 25. 1956 United States Patent O 1 2,841,187 RANDOM TEXTURE PILE FABRIC David Karpod, Blauvelt, Herbert Bridgman, Yonkers,

and Emory P. Mersereau, Jr., Thomwood, N. Y., assgnors to Mohasco Industries, Inc., a corporation of New York Application January 23, 1956, Serial No. 560,476

1 Claim. (Cl. 139-403) This invention relates to pile fabrics and more particularly to pile fabrics having a random texture.

An object is to provide a pile fabric having a novel and improved appearance.

Another object is to provide a novel and improved method of producing a pile fabric on a loom of the type in which the pile warps are bound over pile forming wires.

Another object is to provide a pile fabric in which pile loops of varying heights are randomly distributed over the pile area.

The nature of the invention will be better understood -by referring to the following description, taken in connection with the accompanying drawing, in which a specitic embodiment has been set forth for purposes of illustration.

In the drawing:

Fig. l is a side elevation of `a series of pile wires to be used in making the fabric;

Fig. 2 is a diagrammatic view illustrating one heddling sequence that may be used;

Fig. 3 is a warpwise section of a fabric embodying the present invention; and

Fig. 4 is a fillerwise section of the fabric.

Referring to the drawing more in detail Fig.' l shows a sequence of pile forming wires in which wire 1 is a wavy type wire having a wavy or contoured top surface 2. Wire 3 is a tipped wire having a low shedportion 4 and a high top 5 adapted to pull or rob yarn from the preceding pile row when the wire is withdrawn. Wire 6 is a straight wire of intermediate height.

The fabric according to the present invention may be woven on a standard velvet or Wilton loom having mechanism for inserting and withdrawing the pile wires in succession and to form pile loops over the successive wires which are bound into a woven backing by the usual filler shots. Successive pile warps are separated by a sequence of chain warps and stulfer warps to be described.

The wavy wires 1 are so designed that not more than two successive pile loops are of the same height and the various loops along the wire are of several (seven or eight) different heights. Also the various wavy wires used in the weaving cycle may be differently shaped vso as to avoid any appearance of regularity in pile height distribution over the area of the fabric.

In accordance with this invention the pile yarns are comparatively heavy, preferably three ply, and are loosely twisted to make a soft, bulky yarn for the purpose to be described.

The wire sequence may comprise alternate wavy wires 1 and tipped wires 3 or a sequence of wavy wires, tipped wires and straight wires or other sequences as desired.

In a sequence involving a wavy wire followed by a tipped wire the loops are first formed of varying heights on the wavy wire, then as the wavy wire is withdrawn the contour of the wavy wire is transferred to the preceding row of loops by the process lof robbing the yarn therefrom as the loops pass over the high portion of the wire to leave a row of high loops as described in Jackson Patent No. 2,516,465. These high loops are `then pulled down when the succeeding tipped wire 3 is withdrawn.

Because the pile yarns are loosely twisted 'and somewhat soft and springy the various yarn-s do not pull uniformly as expected from the contours of the wires. They v2,841,1871 Patented July l, 1958 are pulled by various amounts depending upon the hardness of the portion of the yarn on the wire and the variations in bind caused by the weave of the backing. Thus the contour row of loops will have variations from the contour of the wavy wire and the tipped wire pulls unevenly on the previous row of loops to produce a random irregularity in loop heights. Both rows accordingly have loops of varying heights randomly distributed over the area of the fabric. Also, due to the loose twist the pulling of the Wires causes the legs of the various pile loops to twist about each other by different amounts and sometimes in different directions.

If the tipped wire is followed by a straight wire the row of loops formed over the tipped wire will be unevenly pulled as above described and will remain of uneven height and the loops formed over the straight wire will be contoured by the following wavy wire, thus forming a series of rows of loops of uneven height randomly distributed over the pile area.

A combination of two wavy wires of different heights followed by a high tipped wire or by a tipped wire and a straight wire may also be used to enhance the random effect.

The random effect is enhanced by a heddling sequence as indicated in Fig. 2 wherein four successive reed dents 10, 11, 12 and 13 are used for each weftwise repeat. The first dent 10 includes a pile warp P, a pair of chain warps C, C and `a stuffer warp S. The second dent 11 contains in order a 'stutfer warp S, a pair of chain warps C, C `and a pile warp P. The third and fourth dents 12 and 13 contain a pair of chain warps C, C and a stufer warp S, but no pile warp.

The product is shown in Figs. 3 and 4 as comprising a series of pile loops 15 of randomly varying heights and twists bound under upper filler shots 16 of a two shot velvet type backing composed of upper filler shots 16 and lower filler shots 17 bound by chain warps C with straight stuler warps S separating the upper and lower filler shots.

It will be noted that each weftwise repeat includes two pile loops 15 which are separated by two pairs of chain warps and two stuffer warps. However, since two dents of each repeat contain four warps each and two dents contain three warps each the various warps will be unevenly spaced. The piles are unevenly spaced as they are present only in the first two dents of each four dent repeat. As shown in Figs. 2 and 4 the iirst and second pile loops (beginning at the left) are more closely spaced than the second and third pile loops. This further enhances the random effect.

What is claimed is:

In the weaving of a pile fabric in which pile loops are formed over pile forming wires, the improvement which comprises weaving pile warps composed of a soft, loosely twisted yarn over a succession lof differently shaped pile forming wires, said wires in each respect including at least one wavy wire followed by a high tipped wire adapted to produce pile loops of varying heights as the wires are successively withdrawn, each weftwise repeat comprising at least four reed dents, and each dent having at least a stuffer warp and a pair of chain warps, two consecutive dents only containing pile warps whereby successive pile warps are unevenly spaced along said wires.

References Cited in the le of this patent UNITED STATES PATENTS 2,516,465 Jackson July 25, 1950 2,576,791 Jackson Nov. 27, 1951 2,709,458 Hoeselbarth May 31, 1955 2,709,460 Hoeselbarth May 3l, 1955 2,713,354 Hoeselbarth July 19, 1955 2,713,877 Jackson July 26, 1955 

